EP0297167A1 - Method and apparatus for producing molten metal from powder state ore - Google Patents
Method and apparatus for producing molten metal from powder state ore Download PDFInfo
- Publication number
- EP0297167A1 EP0297167A1 EP87114305A EP87114305A EP0297167A1 EP 0297167 A1 EP0297167 A1 EP 0297167A1 EP 87114305 A EP87114305 A EP 87114305A EP 87114305 A EP87114305 A EP 87114305A EP 0297167 A1 EP0297167 A1 EP 0297167A1
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- Prior art keywords
- reducing material
- grain size
- furnace
- set forth
- molten metal
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21B—MANUFACTURE OF IRON OR STEEL
- C21B11/00—Making pig-iron other than in blast furnaces
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B5/00—General methods of reducing to metals
- C22B5/02—Dry methods smelting of sulfides or formation of mattes
- C22B5/10—Dry methods smelting of sulfides or formation of mattes by solid carbonaceous reducing agents
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21B—MANUFACTURE OF IRON OR STEEL
- C21B13/00—Making spongy iron or liquid steel, by direct processes
- C21B13/0006—Making spongy iron or liquid steel, by direct processes obtaining iron or steel in a molten state
- C21B13/0013—Making spongy iron or liquid steel, by direct processes obtaining iron or steel in a molten state introduction of iron oxide into a bath of molten iron containing a carbon reductant
- C21B13/002—Reduction of iron ores by passing through a heated column of carbon
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21B—MANUFACTURE OF IRON OR STEEL
- C21B2100/00—Handling of exhaust gases produced during the manufacture of iron or steel
- C21B2100/40—Gas purification of exhaust gases to be recirculated or used in other metallurgical processes
- C21B2100/44—Removing particles, e.g. by scrubbing, dedusting
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21B—MANUFACTURE OF IRON OR STEEL
- C21B2100/00—Handling of exhaust gases produced during the manufacture of iron or steel
- C21B2100/60—Process control or energy utilisation in the manufacture of iron or steel
- C21B2100/66—Heat exchange
Definitions
- the present invention relates generally to a method and apparatus for producing a molten metal from powder state ore. More specifically, the invention relates to a process for smelting powder state ore by utilizing a shaft furnace.
- ratio of powder state ore as a material for producing metal increases.
- ratio of the powder state ore is expected to further increase.
- substantially high temperature race ways are formed around the tuyeres.
- the powder state ore blown into the furnace through the tuyeres is instantly molten in the race ways.
- Molten ore flows down through the reducing material filled section or otherwise is fluidized with the reducing material in the fluidized bed to be rised the tempereature.
- reduction of the ore progresses to refine.
- the density of the molten ore gradually increases.
- the reduced ore repeats solidifying and melting to gradually increase the grain size.
- the increased grain size of the ore moves down through the reducing material filled section. During downward travel, reduction of the ore is completed.
- the temperature of the ore is rised upto the tapping temperature.
- the ore absorbs metalloid, such as Si, Mn.
- separation of the metal component and slag component occurs so that molten metal and slag are separately collected in the bottom of the furnace.
- Such a smelting technique is effective for efficiently producing molten metal from the powder state ore.
- the prior proposed technique has a drawback in that the reducting material to be used has to have a grain size large enough so as not to be blown away by the gas flow.
- the grain size of the reducing material may be variable depending upon the gas flow velocity in the furnace, which as flow velocity varies depending upon the temperature in the furnace, pressure, gas flow amount and so forth.
- the grain size of the reducing material at the border between blown away and not blown away in relation to the gas flow velocity will be hereafter referred to as "gas flow velocity corresponding grain size".
- the grain size of the reducing material to be charged in the shaft furnace is selected to be n-times greater than the gas flow velocity corresponding grain size. In such cases the reducing material having smaller grain size than that n-times of the gas flow velocity corresponding grain size will never used. On the other hand, even when the reducing material which has smaller grain size than the gas flow velocity corresponding grain size, such small grain size reducing material may be easily blown away with the exhausting gas. This apparently increase the cost for producing the molten metal.
- temperature and composition of the molten metal are variable depending upon the temperature in the reducing material filled section of the furnace. Therefore, in order to stably produce high quality molten metal, it is essential to control the temperature of the reducing material filled section.
- the Japanese Patent First (unexamined) Publication (Tokkai) Showa 62-56537 discloses a method for producing molten metal from powder state ore by forming the fluidized bed of the reducing material and the reducing material filled section in the shaft furnace.
- the disclosed system cannot control the temperature of the reducing material filled section. Therefore, it was not possible to stably perform production of the molten metal and maintain the quality of the produced molten metal at satisfactorily high level.
- Another object of the invention is to provide a method and apparatus for producing molten metal from powder state ore, which can control temperature of reducing material filled section in the shaft furnace so as to control temperature and composition of the molten metal.
- the present invention utilizes the reducing material having grain size greater than that n-types of the gas blow velocity corresponding grain size to charge from the top of a shaft furnace for forming fluidized bed at the upper section of the furnace and a reducing material filled section below the fluidized bed.
- the invention also takes the reducing material having smaller grain size to be blown into the furnace through tuyeres.
- the shaft furnace may be provided vertically offset two groups of tuyeres. On group of tuyeres are directed to the fluidized bed section formed in the shaft furnace and the other group is directed to the solid state reducion material filled section. The smaller rain size reducing material is separately blown into the fluidized bed section and solid state reducing material filled section depending upon grain distribution of the reducing material charged through the top of the furnace.
- a furnace for producing molten metal from powder state ore comprises a furnace chamber filled with a carbon containing reducing material as a burden, to form a fluidized bed and solid burden layer below the fluidized bed, the burden having a grain size greater than a predetermined border grain size which is determined in relation to gas flow velocity in the furnace, a first tuyere directed to the fluidized bed, a second tuyere directed to the solid burden layer, first means associated with the first tuyere for supplying the latter a mixture of an oxygen containing gas, powder state ore and reducing material dust which has grain size smaller than the border grain size, and second means associated with the second tuyere for supplying the latter a mixture of the oxygen containing gas and the reducing material dust.
- a furnace may further comprise a reducing material dust source means for distributing the reducing material dust for the first and second means at respectively controlled distribution rate.
- the reducing material dust source means determines the distribution rate of the reducing material dust for the first and second tuyere depending upon a given tapping temperature of the molten metal.
- the reducing material dust source means determines the distribution rate of the reducing material dust for the first and second tuyeres depending upon a given desired Si concentration of the molten metal to be produced.
- the reducing material source means increases the distribution rate of the reducing material dust for the second tuyere when the molten metal temperature is lower than the desired tapping temperature and decreases the distribution rate of the reducing material dust for the second tuyere when the molten metal temperature is higher than the desired tapping temperature.
- the reducing material dust source means determines the distribution rate of the reducing material dust for the first and second tuyeres depending upon a given desired Si concentration of the molten metal to be produced.
- the border grain size is determined relative to a minimum grain size of the burden which is not blown away from the furnace with an exhaust gas.
- the border grain size is set at a value n-times greater than the minimum grain size.
- the border grain size of the burden is set at 3 mm diameter.
- the reducing material dust source means is designed for collecting the reducing material dust contained in an exhaust gas of the furnace for recirculating the collected dust through the first and second tuyeres.
- a method for producing molten metal from powder state ore comprising the steps of: defining a furnace chamber filled with a carbon containing reducing material as a burden, to form a fluidized bed and solid burden layer below the fluidized bed, the burden having a grain size greater than a predetermined border grain size which is determined in relation to gas flow velocity in the furnace; supplying a mixture of an oxygen containing gas, powder state ore and reducing material dust which has grain size smaller than the border grain size to a first tuyere directed to the fluidized bed; and supplying a mixture of the oxygen containing gas and the reducing material dust through a second tuyere directed to the solid burden layer.
- the first embodiment of a shaft furnace arrangement is particularly designed for smelting and/or reducing power state ore for obtaining molten metal.
- a shaft furnace 6 is employed for implementing the preferred process of smelting operation.
- a reducing material pre-treatment furnace 14 is also provided for performing pre-treatment of solid state carbon containing reducing material, such as coke. In the pre-treatment furnace 14, it may be performed pre-heating of the reducing material.
- the pre-treatment for the reducing material to be performed in the pre-treatment furnace also includes classifying or sizing of the reducing material.
- Reducing material having grain size larger than or equal to n-times of gas flow velocity corresponding grain size is selected to be transferred through a reducing material outlet 15 of the pre-treatment furnace 14 and a reducing material transferring passage way 15a, to be charged into the shaft furnace as a burden of the furnace.
- the reducing material charged in the shaft furnace 6 forms fluidized bed 5 at the upper section 5 and solid state reducing material filled section 4, which fuildized bed is formed above the solid state reducing material filled section.
- the gas flow velocity corresponding grain size of the solid state reducing material may be arithmetically derived on the basis of the temperature, pressure and as flow amount, gas flow velocity in the furnace, apprarent density of the reducing material, density of gas and viscosity coefficient, utilizing Allen's formula or Newton's formula.
- the grain size of the solid state reducing material to be charged to the furnace 6 is selected to be larger than or equal to twice of the as gas flow velocity corresponding grain size.
- the shaft furnace arrangement further includes an ore pre-treatment furnace 16 which performs pre-treatment for powder state ore.
- an ore pre-treatment furnace 16 which performs pre-treatment for powder state ore.
- the pre-fluidization and pre-reduction of the ore is performed.
- the pre-treated ore is transferred through the outlet 17 and an ore passage way 17a as a constitutent of the burden to be charged through the top of furnace.
- Part of pre-treated ore is deeivered through an ore passage way 17b to be introduced into the fluidized bed 5 in the furnace.
- the shaft furnace 6 is provided vertically offset two groups of tuyeres 3 and 8.
- One group of tuyeres 3 are located at lower elevation than others 8 and directed to the solid state reducing material filled section 4.
- the other group of tuyeres 8 are directed toward the fluidized bed 5.
- the tuyeres 3 located at the lower elevation will be hereafter referred to as “lower tuyeres” and the other tuyeres 8 located at upper elevation will be hereafter referred to as "upper tuyeres”.
- the lower and upper tuyeres 3 and 8 are respectively connected to an oxygen containing gas source 2 to introduce therefrom oxygen containing reduction gas through gas passage ways 2a and 2b.
- the oxygen containing gas introduced into the furnace through the upper tuyeres 8 serves for fluidization of the reduction material to form the fluidized bed.
- the oxygen containing gas introduced into the furnace via the lower tuyeres 3 serves for reducing the ore travelling through the solid state reducing material filled section 4.
- the ore passage way 17a is connected to the gas passage ways 2b. Therefore, the powder state ore fed through the ore passage way 17a is introduced into the as passage ways 2b and is blown into the fluidized bed 5 in the furnace 6 via the upper tuyeres 8.
- the ore introduced into the fluidized bed 5 is fluidized to drop through the solid state reducing material filled section 5.
- the ore is molten and reduced.
- molten metal 10 and slag 11 are separated to be separately corrected in the bottom of the furnace.
- the molten metal 10 collected in the bottom of the shaft furnace 6 is tapped via tapping notch 12.
- the reducing material having the grain size smaller than n-times of the gas flow velocity corresponding grain size is collected by a collector 20 and fed through a reducing dust passage way 21.
- the passage way 21 is connected to the gas passage ways 2a and 2b.
- the ratio of the reducing material to be introduced into the gas passage way 2a and 2b may be adjusted in view of the grain distribution of the reducing material to be charged through the reducing material ransferring passage way 15a so that the temperature in the solid state reducing material filled section 4 can be controlled to be adapted for the moltlen metal to be prodjced.
- the exhaust gas introduced into the reducing material pre-treatment furnace is utilized as distillation gas for distilling the reducing material in the pre-treatment.
- Grain Size Grain Distribution 20 - 10 mm 34% 10 - 5 mm 27% 5 - 1 mm 24% -1 mm 15%
- the gas flow velocity corresponding grain size as derived was 0.5 mm.
- the reducing material of 20 to 1 mm grain size is charged through the top of the shaft furnace.
- the reducing material having grain size smaller than 1 mm was introduced into the furnace through the upper and lower tuyeres 3 and 8.
- Overall charge amount of the reducing material was 1040 kg/h.
- the amount of the reducing material to be introduced into the fluidized bed through the upper tuyeres 8 was 95 kg/h (9.1% of overall reducing material amount).
- the amount of the reducing matereial to be introduced into the solid state reducing material filled section 4 was 16 kg/h (5.9% of the overall amount of the reducing material). From the condition set forth above, 11.8 tons on pig iron could be produced in per day.
- Grain Size Grain Distribution 20 - 10 mm 28% 10 - 5 mm 28% 5 - 1 mm 25% -1 mm 19%
- the gas flow velocity corresponding grain size as derived was 0.5 mm.
- the reducing material of 20 to 1 mm grain size is charged through the top of the shaft furnace.
- the reducing material having grain size smaller than 1 mm was introduced into the furnace through the upper and lower tuyeres 3 and 8.
- Overall charge amount of the reducing material was 997 kg/h.
- the amount of the reducing matereial to be introduced into the fluidized bed through the upper tuyeres 8 was 78 kg/h (7.8% of overall reducing matereial amount).
- the amount of the reducing material to be introduced into the solid state reducing material to be introduced into the solid state reducing material filled section 4 was 111 kg/h (11.1% of the overall amount of the reducing material). From the condition set forth above, 11.2 tons on pig iron could be produced in per day.
- the small grain size reducing material introduced into the fluidized bed 5 becomes high temperature particle. Since the powder state ore is introduced into the fluidized bed 5, together with the reducing material. the molten ore tends to adhere on the surface of the small grain size reducing material. This makes reduction of the ore more efficient.
- operation is performed by charging reducing material of grain size greater than or equal to 3 mm diameter.
- the reducing material of the grain size smaller than 3 mm diameter is discharged through the upper and the lower tuyeres 8 and 3.
- classification of the reducing material may be performed in the reducing material pre-treatment furnace and associated classification device.
- experiment is performed utilizing the shaft-type reduction furnace which has 1.2 m of internal diameter, 5 m of height and about 10 tons of production capacity of pig iron per day, which, in turn, has a production capacity for about 5 tons of ferrochromium per day.
- the large grain size reducing material was charged through the top of the furnace.
- the small grain size reducing material was then blown into the fluidized bed 5 and the solid state reducing material filled section 4 via the upper and lower tuyeres 8 and 3. Distribution rate of the small grain size reducing material was adjusted depending upon the temperature of the molten metal to produce.
- the total consumption of the reducing material could be decreased.
- the tapping temperature and Si concentration of the molten metal can be maintained at narrower variation range in relation to the desired tapping temperature and desired Si concentration, in comparision with the variation range of the comparative examples.
- Fig. 2 shows the second embodiment of the shaft furnace arrangement according to the invention, which implements the preferred smelting process for producing molten metal from powder state ore.
- the elements of the same construction and same functions to that of the foregoing first embodiment are represented by the same reference numerals to the foregoing first embodiment.
- the detailed description will be neglected in order to avoid redundancy of the recitation.
- the shaft furnace arrangement of Fig. 2 is characterized by a dust collecting unit 30.
- the dust collecting unit 30 collects dust of reducing material which flow away from the charged reducing material layer with the exhaust gas.
- the dust collecting unit 30 receovers the reducing material dust and recirculate to the passage 21.
- the dust collecting unit 30 may feed the high temperature exhaust gas to the reducing material pre-treatment furnace (not shown in Fig. 2) and the ore pre-treatment furnace (not shown in Fig 2) for utilizing the heat of the exhaust gas in pre-treatment.
- the passage way 21 is branched to have two branches 21a and 21b at a distribution unit 31.
- the branch 21a is connected to the gas flow passage way 2a and the branch 21b is connected to the gas flow passage way 2b.
- a gas distribution unit 32 is disposed between the gas flow passage ways 2a and 2b for adjusting distribution of the oxygen containing gas to flow therethrough.
- the amount of the samll grain size reducing material to be distributed to the branches 21a and 21b is so controlled as to vary so as to control consumption of the charged large grain size reducing materials. Namely, when the large grain size reducing material is reduced to cause lowering of the molten metal tempereature to lower the quality of the produced molten metal, the amount to be derived to the solid state reducing material filled section 4 via the branch 21a and the lower tuyeres 3, is increased. By increasing of the small grain size reducing material in the solid state reducing material filled section 4. By this combustion occurs both in the small and large grain size reducing materials so as to reduce required amount of the large grain size reducing material for maintaining the temperature of the solid state reducing material filled section 4 at desired temperature.
- experiment was performed by utilizing a shaft type reduction furnace 6 which has a capacity for producing about 10 tons of pig iron per day and about 5 tons of ferrochromium.
- iron ore from Australia and chromite from South Africa composition of which are shown in the appended table 1, are used for producing pig iron and ferrochromium.
- the amount of the small grain size reducing material to be distributed to the fluidized bed 5 and the reducing material filled section 4 were adjusted depending upon the molten metal temperature and Si concentration.
- the appended table 3 shows composition of the dust used in smelting operation for the aforementioned ores.
- comparative experiments were performed. The results of the experimentations of the preferred process and the comparative examples are shown in the appended table 4.
- distribution of amount of the small grain size reducing material to be blown through the upper tuyeres 8 and the lower tuyeres 3 are adjusted in view of the tapping temperature and Si concentration.
- the adjustment range of the distribution of the amount of the small grain size reducing material was 20 to 80% in both of the upper and lower tuyeres.
- the distribution of the amount of the small grain size reducing material to be blown through the upper and lower tuyeres are adjusted in a range of 0 to 100% in view of the tapping temperature.
- Figs. 3 and 4 show variation of tapping temperature and Si concentration in the comparative example 5 and the example 6.
- b desired tapping temperature ⁇ :distribution rate of the small grain size reducing material for the lower tuyere relative to the total amount of the small grain size reducing material to be discharged into the furnace.
- substantially constant and high quality of molten metal can be produced with high efficiency of the reducing material, such as coal or coke by discharging controlled distribution of the small grain size reducing material which tends to be blown away if charged from the top of the furnace as a burden. Therefore, the present invention fulfills all of the objects and advantages sought therefor.
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Abstract
Description
- The present invention relates generally to a method and apparatus for producing a molten metal from powder state ore. More specifically, the invention relates to a process for smelting powder state ore by utilizing a shaft furnace.
- In the recent years, ratio of powder state ore as a material for producing metal increases. Especially, according to advance of ore dressing techniques, ratio of the powder state ore is expected to further increase. In this viewpoint, there has been proposed technique for smelting the powder state ore in a shaft furnace filled with carbon containing reducing material, such as coal or coke.
- Smelting process utilizing a shaft furnace has been developped and proposed. In the known process, solid state carbon containing reducing material is charged through the top of the furnace. To the furnace filled with the carbon containing reducting material, oxygen containing gas is blown through tuyeres in order to form a fluidized bed at the upper section of the furnace. Below the fluidized bed, the reduction material filled section is formed. The powder state ore is also blown into the furnace to perform smelting operation.
- By blowing the oxygen containing gas, substantially high temperature race ways are formed around the tuyeres. The powder state ore blown into the furnace through the tuyeres is instantly molten in the race ways. Molten ore flows down through the reducing material filled section or otherwise is fluidized with the reducing material in the fluidized bed to be rised the tempereature. During fluidization, reduction of the ore progresses to refine. According to progress of reduction, the density of the molten ore gradually increases. At the same time, the reduced ore repeats solidifying and melting to gradually increase the grain size. The increased grain size of the ore moves down through the reducing material filled section. During downward travel, reduction of the ore is completed. At the same time, the temperature of the ore is rised upto the tapping temperature. On the other hand, during the aforementioned reduction process, the ore absorbs metalloid, such as Si, Mn. Furthermore, during the reduction process, separation of the metal component and slag component occurs so that molten metal and slag are separately collected in the bottom of the furnace.
- Such a smelting technique is effective for efficiently producing molten metal from the powder state ore. However, the prior proposed technique has a drawback in that the reducting material to be used has to have a grain size large enough so as not to be blown away by the gas flow. The grain size of the reducing material may be variable depending upon the gas flow velocity in the furnace, which as flow velocity varies depending upon the temperature in the furnace, pressure, gas flow amount and so forth. The grain size of the reducing material at the border between blown away and not blown away in relation to the gas flow velocity will be hereafter referred to as "gas flow velocity corresponding grain size". In the practical operation, in consideration of fluctuation of the gas flow velocity, the grain size of the reducing material to be charged in the shaft furnace is selected to be n-times greater than the gas flow velocity corresponding grain size. In such cases the reducing material having smaller grain size than that n-times of the gas flow velocity corresponding grain size will never used. On the other hand, even when the reducing material which has smaller grain size than the gas flow velocity corresponding grain size, such small grain size reducing material may be easily blown away with the exhausting gas. This apparently increase the cost for producing the molten metal.
- On the other hand, temperature and composition of the molten metal are variable depending upon the temperature in the reducing material filled section of the furnace. Therefore, in order to stably produce high quality molten metal, it is essential to control the temperature of the reducing material filled section.
- The Japanese Patent First (unexamined) Publication (Tokkai) Showa 62-56537 discloses a method for producing molten metal from powder state ore by forming the fluidized bed of the reducing material and the reducing material filled section in the shaft furnace. However, the disclosed system cannot control the temperature of the reducing material filled section. Therefore, it was not possible to stably perform production of the molten metal and maintain the quality of the produced molten metal at satisfactorily high level.
- Therefore, it is an object of the present invention to provide a method and apparatus for producing molten metal from powder state ore in a shaft furnace, in which solid state carbon containing reducing material can be effectively used for obtaining improved reduction efficiency in view of the consumed reducing material.
- Another object of the invention is to provide a method and apparatus for producing molten metal from powder state ore, which can control temperature of reducing material filled section in the shaft furnace so as to control temperature and composition of the molten metal.
- In order to accomplish the aforementioned and other objects, the present invention utilizes the reducing material having grain size greater than that n-types of the gas blow velocity corresponding grain size to charge from the top of a shaft furnace for forming fluidized bed at the upper section of the furnace and a reducing material filled section below the fluidized bed. The invention also takes the reducing material having smaller grain size to be blown into the furnace through tuyeres.
- In the preferred construction, the shaft furnace may be provided vertically offset two groups of tuyeres. On group of tuyeres are directed to the fluidized bed section formed in the shaft furnace and the other group is directed to the solid state reducion material filled section. The smaller rain size reducing material is separately blown into the fluidized bed section and solid state reducing material filled section depending upon grain distribution of the reducing material charged through the top of the furnace.
- According to one aspect of the invention, a furnace for producing molten metal from powder state ore comprises a furnace chamber filled with a carbon containing reducing material as a burden, to form a fluidized bed and solid burden layer below the fluidized bed, the burden having a grain size greater than a predetermined border grain size which is determined in relation to gas flow velocity in the furnace, a first tuyere directed to the fluidized bed, a second tuyere directed to the solid burden layer, first means associated with the first tuyere for supplying the latter a mixture of an oxygen containing gas, powder state ore and reducing material dust which has grain size smaller than the border grain size, and second means associated with the second tuyere for supplying the latter a mixture of the oxygen containing gas and the reducing material dust.
- A furnace may further comprise a reducing material dust source means for distributing the reducing material dust for the first and second means at respectively controlled distribution rate.
- The reducing material dust source means determines the distribution rate of the reducing material dust for the first and second tuyere depending upon a given tapping temperature of the molten metal. The reducing material dust source means determines the distribution rate of the reducing material dust for the first and second tuyeres depending upon a given desired Si concentration of the molten metal to be produced. The reducing material source means increases the distribution rate of the reducing material dust for the second tuyere when the molten metal temperature is lower than the desired tapping temperature and decreases the distribution rate of the reducing material dust for the second tuyere when the molten metal temperature is higher than the desired tapping temperature.
- In the alternative, the reducing material dust source means determines the distribution rate of the reducing material dust for the first and second tuyeres depending upon a given desired Si concentration of the molten metal to be produced.
- In the preferred embodiment, the border grain size is determined relative to a minimum grain size of the burden which is not blown away from the furnace with an exhaust gas. In practice, the border grain size is set at a value n-times greater than the minimum grain size. In the alternative, the border grain size of the burden is set at 3 mm diameter.
- It is preferably and advantageous that the reducing material dust source means is designed for collecting the reducing material dust contained in an exhaust gas of the furnace for recirculating the collected dust through the first and second tuyeres.
- According to another aspect of the invention, a method for producing molten metal from powder state ore comprising the steps of:
defining a furnace chamber filled with a carbon containing reducing material as a burden, to form a fluidized bed and solid burden layer below the fluidized bed, the burden having a grain size greater than a predetermined border grain size which is determined in relation to gas flow velocity in the furnace;
supplying a mixture of an oxygen containing gas, powder state ore and reducing material dust which has grain size smaller than the border grain size to a first tuyere directed to the fluidized bed; and
supplying a mixture of the oxygen containing gas and the reducing material dust through a second tuyere directed to the solid burden layer. - The present invention will be understood more fully from the detailed description given herebelow and from the accompanying drawings of the preferred embodiments of the invention, which, however, should not be taken to limit the invention to the specific embodiment of the invention, but are for explanation and understanding only.
- In the drawings:
- Fig. 1 is a diagramatical illustration of the first embodiment of a shaft furnace arrangement which implements the preferred embodiment of method for producing molten metal from powder state ore through smelting process;
- Fig. 2 is a diagramatical illustration of the second embodiment of a shaft furnace arrangement for implementing the preferred smelting process for producing molten metal from powder state ore; and
- Fig. 3 and 4 shows variation of Si content and tapping tempereature through operation period in the smelting process of the second embodiment and a comparative example.
- Referring now to the drawings, particularly to Fig. 1, the first embodiment of a shaft furnace arrangement is particularly designed for smelting and/or reducing power state ore for obtaining molten metal. A
shaft furnace 6 is employed for implementing the preferred process of smelting operation. A reducing material pre-treatmentfurnace 14 is also provided for performing pre-treatment of solid state carbon containing reducing material, such as coke. In thepre-treatment furnace 14, it may be performed pre-heating of the reducing material. The pre-treatment for the reducing material to be performed in the pre-treatment furnace also includes classifying or sizing of the reducing material. Reducing material having grain size larger than or equal to n-times of gas flow velocity corresponding grain size, is selected to be transferred through a reducingmaterial outlet 15 of thepre-treatment furnace 14 and a reducing material transferring passage way 15a, to be charged into the shaft furnace as a burden of the furnace. The reducing material charged in theshaft furnace 6 formsfluidized bed 5 at theupper section 5 and solid state reducing material filledsection 4, which fuildized bed is formed above the solid state reducing material filled section. - The gas flow velocity corresponding grain size of the solid state reducing material may be arithmetically derived on the basis of the temperature, pressure and as flow amount, gas flow velocity in the furnace, apprarent density of the reducing material, density of gas and viscosity coefficient, utilizing Allen's formula or Newton's formula. In the shown embodiment, the grain size of the solid state reducing material to be charged to the
furnace 6 is selected to be larger than or equal to twice of the as gas flow velocity corresponding grain size. - The shaft furnace arrangement further includes an
ore pre-treatment furnace 16 which performs pre-treatment for powder state ore. In the pre-treatment for powder state ore in theore pre-treatment furnace 16, the pre-fluidization and pre-reduction of the ore is performed. The pre-treated ore is transferred through theoutlet 17 and anore passage way 17a as a constitutent of the burden to be charged through the top of furnace. Part of pre-treated ore is deeivered through anore passage way 17b to be introduced into thefluidized bed 5 in the furnace. - The
shaft furnace 6 is provided vertically offset two groups oftuyeres tuyeres 3 are located at lower elevation thanothers 8 and directed to the solid state reducing material filledsection 4. On the other hand, the other group oftuyeres 8 are directed toward thefluidized bed 5. Thetuyeres 3 located at the lower elevation will be hereafter referred to as "lower tuyeres" and theother tuyeres 8 located at upper elevation will be hereafter referred to as "upper tuyeres". - The lower and
upper tuyeres gas source 2 to introduce therefrom oxygen containing reduction gas throughgas passage ways upper tuyeres 8 serves for fluidization of the reduction material to form the fluidized bed. On the other hand, the oxygen containing gas introduced into the furnace via thelower tuyeres 3 serves for reducing the ore travelling through the solid state reducing material filledsection 4. - The
ore passage way 17a is connected to thegas passage ways 2b. Therefore, the powder state ore fed through theore passage way 17a is introduced into the aspassage ways 2b and is blown into thefluidized bed 5 in thefurnace 6 via theupper tuyeres 8. The ore introduced into thefluidized bed 5 is fluidized to drop through the solid state reducing material filledsection 5. During drop through the solid state reducing material filledsection 4, the ore is molten and reduced. Furthermore, during drop,molten metal 10 and slag 11 are separated to be separately corrected in the bottom of the furnace. Themolten metal 10 collected in the bottom of theshaft furnace 6 is tapped via tappingnotch 12. - On the other hand, the reducing material having the grain size smaller than n-times of the gas flow velocity corresponding grain size, is collected by a
collector 20 and fed through a reducingdust passage way 21. Thepassage way 21 is connected to thegas passage ways gas passage way section 4 can be controlled to be adapted for the moltlen metal to be prodjced. - During the smelting operation, exhaust gas rises through the solid state reducing material filled
section 4 and thefluidized bed 5 is collected and circulated into the reducing materialpre-treatment furnace 14 and theore pre-treatment furnace 16. The exhaust gas introduced into the reducing material pre-treatment furnace is utilized as distillation gas for distilling the reducing material in the pre-treatment. - In order to confirm the performance of the aforementioned first embodiment of the smelting process, experiments are performed. In the experimentation, the shaft furnace of 1.2m diameter furnace was used.
-
- 1) Powder State Ore
Brand: MBR-PB
Grain Size: 150 mesh or elow; - 2) Carbon Containing Reducing Material
Kind: South African Coal - Grain Size: Grain Distribution
20 - 10 mm 34%
10 - 5mm 27%
5 - 1mm 24%
-1mm 15%
- In the experimentation of the example 1, the gas flow velocity corresponding grain size as derived was 0.5 mm. The reducing material of 20 to 1 mm grain size is charged through the top of the shaft furnace. The reducing material having grain size smaller than 1 mm was introduced into the furnace through the upper and
lower tuyeres upper tuyeres 8 was 95 kg/h (9.1% of overall reducing material amount). The amount of the reducing matereial to be introduced into the solid state reducing material filledsection 4 was 16 kg/h (5.9% of the overall amount of the reducing material). From the condition set forth above, 11.8 tons on pig iron could be produced in per day. -
- 1) Powder State Ore
Brand: MBR-PB
Grain Size: 150 mesh or elow; - 2) Carbon Containing Reducing Material
Kind: South African Coal - Grain Size: Grain Distribution
20 - 10 mm 28%
10 - 5 mm 28%
5 - 1 mm 25%
-1 mm 19%
- In the experimentation of the example 2, the gas flow velocity corresponding grain size as derived was 0.5 mm. The reducing material of 20 to 1 mm grain size is charged through the top of the shaft furnace. The reducing material having grain size smaller than 1 mm was introduced into the furnace through the upper and
lower tuyeres upper tuyeres 8 was 78 kg/h (7.8% of overall reducing matereial amount). The amount of the reducing material to be introduced into the solid state reducing material to be introduced into the solid state reducing material filledsection 4 was 111 kg/h (11.1% of the overall amount of the reducing material). From the condition set forth above, 11.2 tons on pig iron could be produced in per day. - As will be seen herefrom, since the grain size of the reducing material charged through the top of the furnace was smaller than that used in the former example 1, the small grain size reducing material to be introduced into the solid state reducing material filled
section 4 was increased in comparision with that in the example 1. - In either examples. the small grain size reducing material introduced into the
fluidized bed 5 becomes high temperature particle. Since the powder state ore is introduced into thefluidized bed 5, together with the reducing material. the molten ore tends to adhere on the surface of the small grain size reducing material. This makes reduction of the ore more efficient. - In another embodiment of the smelting process of the molten metal from the powder state ore, operation is performed by charging reducing material of grain size greater than or equal to 3 mm diameter. The reducing material of the grain size smaller than 3 mm diameter is discharged through the upper and the
lower tuyeres - In order to implement the another embodiment of the smelting method, experiment is performed utilizing the shaft-type reduction furnace which has 1.2 m of internal diameter, 5 m of height and about 10 tons of production capacity of pig iron per day, which, in turn, has a production capacity for about 5 tons of ferrochromium per day. The large grain size reducing material was charged through the top of the furnace. The small grain size reducing material was then blown into the
fluidized bed 5 and the solid state reducing material filledsection 4 via the upper andlower tuyeres - As will be seen from the table 2, it should be appreciated that, by using large grain size reducing material as burden to be charged through the top of furnace for forming the fluidized bed and the solid state reducing material filled section in the furnace and blowing the small grain size reducing material through the tuyeres at controlled distribution rate, the total consumption of the reducing material could be decreased. In addition, the tapping temperature and Si concentration of the molten metal can be maintained at narrower variation range in relation to the desired tapping temperature and desired Si concentration, in comparision with the variation range of the comparative examples.
- Fig. 2 shows the second embodiment of the shaft furnace arrangement according to the invention, which implements the preferred smelting process for producing molten metal from powder state ore. In the shown second embodiment, the elements of the same construction and same functions to that of the foregoing first embodiment are represented by the same reference numerals to the foregoing first embodiment. For the elements represented by the common reference numerals to the foregoing Fig. 1, the detailed description will be neglected in order to avoid redundancy of the recitation.
- The shaft furnace arrangement of Fig. 2 is characterized by a
dust collecting unit 30. Thedust collecting unit 30 collects dust of reducing material which flow away from the charged reducing material layer with the exhaust gas. Thedust collecting unit 30 receovers the reducing material dust and recirculate to thepassage 21. On the other hand, thedust collecting unit 30 may feed the high temperature exhaust gas to the reducing material pre-treatment furnace (not shown in Fig. 2) and the ore pre-treatment furnace (not shown in Fig 2) for utilizing the heat of the exhaust gas in pre-treatment. - In the shown embodiment, the
passage way 21 is branched to have twobranches branch 21a is connected to the gasflow passage way 2a and thebranch 21b is connected to the gasflow passage way 2b. Agas distribution unit 32 is disposed between the gasflow passage ways - Though it is not clearly shown in Fig. 2, it may be possible to connect the dust collecting unit to the reducing material pre-treatment furnace to receive therefrom the small grain size reducing material which has grain size smaller than n-times of the gas flow velocity corresponding grain size.
- In the shown construction, the amount of the samll grain size reducing material to be distributed to the
branches section 4 via thebranch 21a and thelower tuyeres 3, is increased. By increasing of the small grain size reducing material in the solid state reducing material filledsection 4. By this combustion occurs both in the small and large grain size reducing materials so as to reduce required amount of the large grain size reducing material for maintaining the temperature of the solid state reducing material filledsection 4 at desired temperature. This expands the period to stay the large grain size reducing matereial in the reducing material filledsection 4. This makes it possible to rise the temperature in the reducing material filledsection 4. This rises the temperature of the molten metal passing through the reducing material filled section and thus can stably maintain the composition of the molten metal. On the other hand, when excessive volume of large grain size reducing material is the reducing material filled section, the temperature of the molten metal tends to be excessively high. In this case, the small grain size reducing material to be introduced into the reducing material filledsection 4 is reduced. By this, consumption of the large grain size reducing material is increased to lower the temperature in the reducing material filled section and whereby lower the temperature of the molten metal. - In order to check the performance of the shown second embodiment of the shaft furnace and the preferred smelting process, experiment was performed by utilizing a shaft
type reduction furnace 6 which has a capacity for producing about 10 tons of pig iron per day and about 5 tons of ferrochromium. In the experimentation. iron ore from Australia and chromite from South Africa, composition of which are shown in the appended table 1, are used for producing pig iron and ferrochromium. - The amount of the small grain size reducing material to be distributed to the
fluidized bed 5 and the reducing material filledsection 4 were adjusted depending upon the molten metal temperature and Si concentration. The appended table 3 shows composition of the dust used in smelting operation for the aforementioned ores. In order to compare with the results obtained from the preferred process, comparative experiments were performed. The results of the experimentations of the preferred process and the comparative examples are shown in the appended table 4. - In the comparative examples 3 and 5, smelting operations are performed without blowing into the small grain size reducing material through the tuyeres. In the comparative example 4, the distribution rate of the small grain size reducing material as fixed at 1 : 1 to blow into the
fluidized base 5 and the reducing material filledsection 4. - In the example 5, distribution of amount of the small grain size reducing material to be blown through the
upper tuyeres 8 and thelower tuyeres 3 are adjusted in view of the tapping temperature and Si concentration. In this case, the adjustment range of the distribution of the amount of the small grain size reducing material was 20 to 80% in both of the upper and lower tuyeres. On the other hand, in the examples 6 and 7, the distribution of the amount of the small grain size reducing material to be blown through the upper and lower tuyeres are adjusted in a range of 0 to 100% in view of the tapping temperature. - From the experimentation set forth above, it was observed that actual tapping temperature and Si concentration in the comparative examples 3 and 4 did not match the desired values and fluctuate in a wide range. On the other hand, in the examples 5 and 6, the tapping temperature matches the desired value and fluctuated in a small range close to the desired value. In addition, in the examples 7 and 6, the Si concentrations were maintained at substantially narrow range across the desired value. In case of the comparative example 5, both of the tapping temperature and Si concentration fluctuated in substantial range across the desired value. To the contrary, in the example 7, both of the tapping temperature and Si concentration could be maintained in substantially narrow fluctuation range across the desired value.
- The results of experimentation are shown in the appended table 4. As will be seen from the table 4, it would be appreciated that by adjusting the small grain size reducing material distribution at the upper and lower tuyeres, the tapping temperature and Si concentration can be stably maintained at approximately the desired values. Therefore, consumption of the reducing material can be economized.
- Figs. 3 and 4 show variation of tapping temperature and Si concentration in the comparative example 5 and the example 6. In the example 6, the distribution of the amount of the small grain size of the reducing material was derived according to the following formulas:
when a > b + 50
α = 0
when b + 50 > a > b - 50
α = 0.5 - 0.01 x (a - b)
when a < b - 50
α - 1.0
where
a: tapping temperature;
b: desired tapping temperature
α:distribution rate of the small grain size reducing material for the lower tuyere relative to the total amount of the small grain size reducing material to be discharged into the furnace. - As will be seen from Figs. 3 and 4, it would be appreciated that by adjusting the small grain size reducing material distribution at the upper and lower tuyeres the tapping temperature and Si concentration can be maintained approximately at the desired values.
- As will be appreciated herefrom, in the smelting process according to the present invention, substantially constant and high quality of molten metal can be produced with high efficiency of the reducing material, such as coal or coke by discharging controlled distribution of the small grain size reducing material which tends to be blown away if charged from the top of the furnace as a burden. Therefore, the present invention fulfills all of the objects and advantages sought therefor.
- While the present invention has been disclosed in terms of the preferred embodiment in order to facilitate better understanding of the invention, it should be appreciated that the invention can be embodied in various ways without departing from the principle of the invention. Therefore, the invention should be understood to include all possible embodiments and modifications to the shown embodiments which can be embodied without departing from the principle of the invention set out in the appended claims.
TABLE 1 T.Fe T.Cr SiO₂ Aℓ₂O₃ S Ave. Grain Size (mm) IRON ORE (Australia) 66.1 tr 3.2 0.7 0.003 1.23 Chromite (South Africa) 19.2 30.8 3.1 14.5 0.001 0.74 TABLE 2 COM. 1 EXAM.3 COM. 2 EXAM. 4 MOLTEN METAL TO BE PRODUCED PIG IRON FERROCHROMIUM REDUCING MATERIAL DUST DUISTRIBUTION RATE (%) (UPPER TUYERE) --- 0 ∼ 100 --- 0∼100 REDUCING MATERIAL DUST DUISTRIBUTION RATE (%) (LOWER TUYERE) --- 0 ∼ 100 --- 0∼100 CONSUMED COAL AMOUNT 995 912 1884 1785 DESIRED TAPPING TEMP. 1470 1470 1580 1580 ACTUAL TAPPING TEM. 1375 ∼ 1536 1431 ∼ 1511 1507 ∼ 1632 1538 ∼ 1607 DESIRED Si CONCENTRATION 1.0 1.0 2.5 2.5 ACTUAL Si CONCENTRATION 0.31 ∼ 4.3 0.87 ∼ 1.8 1.5 ∼ 5.1 1.5 ∼ 3.0 TABLE 3 C T.Fe CaO SiO₂ Aℓ₂O₃ MgO 53.3 6.1 10.1 17.4 7.5 3.7 TABLE 4 COM. 3 COM. 4 EXAM. 5 EXAM. 6 COM. 5 EXAM.7 MOLTEN METAL TO BE PRODUCED PIG IRON FERROCHROMIUM REDUCING MATERIAL DUST DISTRIBUTION RATE (%) (UPPER) 50 20∼80 0∼100 0∼100 REDUCING MATERIAL DUST DISTRIBUTION RATE (%) (LOWER) 50 20∼80 0∼100 0∼100 COAL CONSUMPTION (kg/t-metal) 987 930 922 903 1875 1780 DESIRED TAPPING TEMP. (° C) 1470 1470 1470 1470 1580 1580 ACTUAL TAPPING TEMP. (° C) 1381 ∼ 1540 1390 ∼ 1532 1417 ∼ 1511 1423 ∼ 1507 1509 ∼ 1624 1543 ∼ 1614 DESIRED Si CONCENTRATION (%) 1.0 1.0 1.0 1.0 2.5 2.5 ACTUAL Si CONCENTRATION (%) 0.27∼3.8 0.27∼3.2 0.53∼2.2 0.84∼1.7 1.7∼4.8 1.9∼3.1
Claims (21)
a furnace chamber filled with a carbon containing reducing material as a burden, to form a fluidized bed and solid burden layer below said fluidized bed, said burden having a grain size greater than a predetermined border grain size which is determined in relation to gas flow velocity in the furnace:
a first tuyere directed to said fluidized bed;
a second tuyere directed to said solid burden layer;
first means associated with said first tuyere for supplying the latter a mixture of an oxygen containing gas, powder state ore and reducing material dust which has grain size smaller than said border grain size; and
second means associated with said second tuyere for supplying the latter a mixture of said oxygen containing gas and said reducing material dust.
defining a furnace chamber filled with a carbon containing reducing material as a burden, to form a fluidized bed and solid burden layer below said fluidized bed, said burden having a grain size greater than a predetermined border grain size which is determined in relation to gas flow velocity in the furnace;
supplying a mixture of an oxygen containing gas, powder state ore and reducing material dust which has grain size smaller than said border grain size to a first tuyere directed to said fluidized bed; and
supplying a mixture of said oxygen containing gas and said reducing material dust through a second tuyere directed to said solid burden layer.
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP62163730A JPS648208A (en) | 1987-06-30 | 1987-06-30 | Production of molten metal from powdery ore |
JP163730/87 | 1987-06-30 | ||
JP21904487A JPH066729B2 (en) | 1987-09-03 | 1987-09-03 | Method for producing molten metal from powdered ore |
JP219044/87 | 1987-09-03 |
Publications (2)
Publication Number | Publication Date |
---|---|
EP0297167A1 true EP0297167A1 (en) | 1989-01-04 |
EP0297167B1 EP0297167B1 (en) | 1993-08-11 |
Family
ID=26489100
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP87114305A Expired - Lifetime EP0297167B1 (en) | 1987-06-30 | 1987-09-30 | Method and apparatus for producing molten metal from powder state ore |
Country Status (7)
Country | Link |
---|---|
US (1) | US5131942A (en) |
EP (1) | EP0297167B1 (en) |
KR (1) | KR950005786B1 (en) |
AU (1) | AU627563B2 (en) |
BR (1) | BR8705045A (en) |
CA (1) | CA1337743C (en) |
DE (1) | DE3787017T2 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2013010725A1 (en) * | 2011-07-21 | 2013-01-24 | Siemens Vai Metals Technologies Gmbh | Melting reduction assembly and method for operating a melting reduction assembly |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
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BE1006828A3 (en) * | 1991-07-12 | 1995-01-03 | Elsen Tooling Ireland Ltd | Method for the preparation of metals, particularly iron, from oxidised ores,at any reduction temperature in a drop reduction furnace |
AT404735B (en) * | 1992-10-22 | 1999-02-25 | Voest Alpine Ind Anlagen | METHOD AND INSTALLATION FOR THE PRODUCTION OF LIQUID PIPE IRON OR LIQUID STEEL PRE-PRODUCTS |
WO2011001282A2 (en) | 2009-06-29 | 2011-01-06 | Bairong Li | Metal reduction processes, metallurgical processes and products and apparatus |
KR101419258B1 (en) * | 2013-07-03 | 2014-07-15 | 주식회사 포스코 | Method for operating blast furnace using sintering desulfuration dust |
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- 1987-09-30 EP EP87114305A patent/EP0297167B1/en not_active Expired - Lifetime
- 1987-09-30 BR BR8705045A patent/BR8705045A/en not_active IP Right Cessation
- 1987-09-30 KR KR1019870010960A patent/KR950005786B1/en not_active IP Right Cessation
- 1987-09-30 DE DE87114305T patent/DE3787017T2/en not_active Expired - Fee Related
- 1987-09-30 CA CA000548243A patent/CA1337743C/en not_active Expired - Fee Related
-
1990
- 1990-04-04 AU AU52595/90A patent/AU627563B2/en not_active Ceased
- 1990-05-04 US US07/518,333 patent/US5131942A/en not_active Expired - Fee Related
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WO2013010725A1 (en) * | 2011-07-21 | 2013-01-24 | Siemens Vai Metals Technologies Gmbh | Melting reduction assembly and method for operating a melting reduction assembly |
CN103687965A (en) * | 2011-07-21 | 2014-03-26 | 西门子Vai金属科技有限责任公司 | Melting reduction assembly and method for operating a melting reduction assembly |
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Also Published As
Publication number | Publication date |
---|---|
DE3787017D1 (en) | 1993-09-16 |
AU627563B2 (en) | 1992-08-27 |
BR8705045A (en) | 1989-03-21 |
KR950005786B1 (en) | 1995-05-31 |
AU5259590A (en) | 1990-08-02 |
EP0297167B1 (en) | 1993-08-11 |
DE3787017T2 (en) | 1993-11-25 |
CA1337743C (en) | 1995-12-19 |
US5131942A (en) | 1992-07-21 |
KR890000672A (en) | 1989-03-15 |
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